Method and system of welding with auto-determined startup parameters

a startup parameter and welding method technology, applied in the field of welding, can solve the problems of undesirable weld joints, aluminum also has a relatively low resistivity, and the workpiece to be welded must be preheated

Active Publication Date: 2006-06-22
ILLINOIS TOOL WORKS INC
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Benefits of technology

[0009] A welding-type system is disclosed and includes a controller configured to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process. While applicable to a number of welding-type processes, the controller is particularly configured to determine an optimum wire feed speed for GMAW-P of alum...

Problems solved by technology

A drawback of GMAW-P with aluminum, however, is that customarily the workpiece to be weld must be preheated.
This undesirable weld joint is a result of the heat at the weld during start-up of the welding process being insufficient to melt the aluminum electrode and the workpiece into a molten pool.
That is, while aluminum has a relatively low melting point, aluminum also has a relatively low resistivity.
As can be appreciated, preheating adds to the time, cost, and complexity of the GMAW-P with aluminum process.
A drawback of this solution is...

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  • Method and system of welding with auto-determined startup parameters

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Embodiment Construction

[0022] Referring to FIGS. 1-2, a GMAW welding system 10 includes a welding power source 12 designed to supply power to a wire feeder 14 through a weld cable 16. The power source is designed to run in one of a number of modes including constant voltage (CV) and constant current (CC). Also connected to the power source is a secondary work weld cable 18 that connects the power source to a clamp 20 designed to connect cable 18 to workpiece 22. Also connected to wire feeder 14 is a welding gun or torch 24 configured to supply consumable welding wire to a weld. Welding system 10 may further include a gas cylinder 26 connected to wire feeder 14 such that shielding gas can be provided through gas hose 28 for the GMAW welding process. It is contemplated that the gas cylinder may be mounted to or in either power source 12 or wire feeder 14. The gas cylinder preferably includes a regulator / flowmeter 29 to regulate the delivery of gas from cylinder 26 through gas hose 28.

[0023] Power source 12...

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Abstract

A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Description

BACKGROUND OF THE INVENTION [0001] The present invention is directed to welding and, more particularly, to a method and system of aluminum welding without preheating of a workpiece. The invention is particularly applicable with pulsed spray transfer welding. [0002] Gas Metal Arc Welding (GMAW), also referred to Metal Inert Gas (MIG) welding, combines the techniques and advantages of Tungsten Inert Gas (TIG) welding's inert gas shielding with a continuous, consumable wire electrode that is delivered to a weld by a wire feeder. An electrical arc is created between the continuous, consumable wire electrode and the workpiece. As such, the consumable wire functions as the electrode in the weld circuit as well as the source of filler metal. Gas Metal Arc Welding is a relatively simple process that allows an operator to concentrate on arc control. Gas Metal Arc Welding may be used to weld most commercial metals and alloys including steel, aluminum, and stainless steel. Moreover, the travel...

Claims

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Application Information

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IPC IPC(8): B23K9/10
CPCB23K9/09B23K9/0953B23K9/10B23K9/125B23K2203/10B23K2103/10
Inventor KAUFMAN, CHARLES L.KLEGIN, MICHAEL T.ROEHL, CHRIS J.
Owner ILLINOIS TOOL WORKS INC
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